Liquid applicator

ABSTRACT

An applicator for a liquid product includes an elongated base having a product cup sized for retaining a single-dose quantity of a liquid product; an applicator cup for receiving an applicator pad; and a channel interconnecting the product cup and the applicator cup. An absorbent applicator pad is disposed in the applicator cup. A liquid product is positively retained in the product cup until it is desired to apply the liquid product.

BACKGROUND OF THE INVENTION

This invention relates generally to a combined storage package andapplicator, and more particularly to a disposable single-dose applicatorfor a liquid product.

Liquid phase products or “liquid products” have many uses in themedical, hygiene, and first aid fields. One example of such a liquidphase product is a “liquid bandage”, that is, a liquid that can beapplied to a wound or burn that then cures to form an protectivebarrier. A liquid bandage can be applied in arbitrary shapes and sizesand can be applied to odd-shaped areas of the body. This saves money andreduces waste compared to fabric or plastic bandages.

This type of product has typically been packaged in multi-dosecontainers, for example an ordinary glass bottle incorporating a brushapplicator. Unfortunately, this kind of package often contains enoughliquid for many scores or even hundreds of individual uses or “doses”.This arrangement is uneconomical if a user wants to keep the liquidproduct readily available in several locations (i.e. at home, at work,or in a car). The product is also subject to spoliation, drying out, orbreakage well before it is fully consumed. Furthermore, because of thenature of the product, reuse can be unsightly or unappealing. Forexample, liquid bandages are often applied with an applicator brush thatis stored in the bottle after it has been put in contact with an openwound, thereby facilitating contamination of the remaining liquid withwound debris.

There have been attempts in the prior art to create single-dosepackages. However, these packages require a separate applicator which ismessy and wasteful.

Accordingly, there is a need for a combined single-dose package andapplicator.

BRIEF SUMMARY OF THE INVENTION

Therefore, it is an object of the invention to provide a package for aliquid product having a built-in applicator.

It is another object of the invention to provide an applicator whichprotects a liquid from exposure until it is intentionally opened.

It is another object of the invention to provide an applicator for asingle dose quantity of a liquid product.

These and other objects are fulfilled by the present invention, which inone embodiment provides an applicator for a liquid product, including anelongated base which has: a product cup sized for retaining asingle-dose quantity of a liquid product; an applicator cup forreceiving an applicator pad; and a channel interconnecting the productcup and the applicator cup. An absorbent applicator pad is disposed inthe applicator cup. Means are provided for positively retaining a liquidproduct in the product cup until it is desired to apply the liquidproduct.

According to another embodiment of the invention, the means forretaining the liquid product include a weak weld formed in the channelbetween the product cup and the applicator cup.

According to another embodiment of the invention, the base is asheet-like member having the product cup, applicator cup, and channelformed therein; and a separator sheet is attached to the base so as toenclose the product cup and channel while leaving the applicator cup atleast partially exposed.

According to another embodiment of the invention, the base and theseparator sheet each are made of a metallic foil; and

the base and the separator sheet are bonded together with an adhesivelayer.

According to another embodiment of the invention, the weak weld isdefined by corresponding portions of the base and the separator sheetaligned with the channel which are attached together less securely thanthe remainder of the base and the separator sheet.

According to another embodiment of the invention, the applicator extendsthrough an opening in the separator sheet.

According to another embodiment of the invention, the product cup isdisposed at a first end of the base and the applicator cup is disposedat a second end of the base.

According to another embodiment of the invention, a portion of the basewhich surrounds the applicator pad is narrowed so as to expose theapplicator pad for convenient use when the cover is opened.

According to another embodiment of the invention, the applicator padincludes a pair of angled sides; and opposed corners of the base at thesecond end thereof are angled to correspond to the shape of theapplicator pad.

According to another embodiment of the invention, opposed corners of thebase at the second end thereof are angled to provide access to theapplicator pad.

According to another embodiment of the invention, the applicator furtherincludes a cover overlying the applicator pad and removably attached tothe applicator, the cover adapted to protect the applicator pad fromexposure until the cover is intentionally opened.

According to another embodiment of the invention, a portion of the coveris attached to the applicator more securely than the remainder of thecover so as to define a hinge tab which remains attached to theseparator sheet when the remainder of the cover is opened.

According to another embodiment of the invention, the applicator furtherincludes a liquid product disposed in the product cup.

According to another embodiment of the invention, the liquid product isa liquid bandage material.

According to another embodiment of the invention, a method of making anapplicator for a liquid product includes: providing an elongated base:molding a product cup sized for retaining a single-dose quantity of aliquid product in the base; molding an applicator cup for receiving anapplicator pad in the base; molding a channel interconnecting theproduct cup and the applicator cup in the base; placing an absorbentapplicator pad in the applicator cup; disposing a liquid product in theproduct cup; and sealing the liquid product in the product cup such thatit will be retained therein until it is desired to apply the liquidproduct.

According to another embodiment of the invention, the step of sealingthe liquid product includes forming a frangible divider in the channelbetween the product cup and the applicator cup.

According to another embodiment of the invention, the method furtherincludes attaching a separator sheet to the base so as to enclose theproduct cup and channel while leaving the applicator cup at leastpartially exposed.

According to another embodiment of the invention, the method furtherincludes: providing the separator sheet with a first layer of hot sealadhesive; and providing the base with a second layer of hot sealadhesive; and applying heat and pressure to the separator sheet and thebase to bond the adhesive layers together.

According to another embodiment of the invention, the weak weld isformed by bonding a selected area of the base and the separator sheetwhich is aligned with the channel together, wherein the selected area isbonded together less securely than the remaining bonded portions of thebase and the separator sheet.

According to another embodiment of the invention, the method furtherincludes removably attaching to the separator sheet a cover whichoverlies the applicator pad and protects it from exposure.

According to another embodiment of the invention, the method furtherincludes attaching a portion of the cover to the separator sheet moresecurely than the remainder of the cover so as to define a hinge tabwhich remains attached to the separator sheet when the remainder of thecover is opened.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be best understood by reference to the followingdescription taken in conjunction with the accompanying drawing figuresin which:

FIG. 1 is a perspective view of a group of applicators constructed inaccordance with a preferred embodiment of the present invention;

FIG. 2 is an enlarged perspective view of one of the applicatorsdepicted in FIG. 1;

FIG. 3 is an exploded perspective view of the applicator of FIG. 1;

FIG. 4 is a side view of an applicator ready for use; and

FIG. 5 a perspective view of the applicator of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings wherein identical reference numerals denotethe same elements throughout the various views, FIG. 1 depicts a sheet10 of connected applicators 12. Individual applicators 12 may beseparated from the sheet 10 by tearing along perforation lines “P”. FIG.2 shows one of the applicators 12 in more detail. The applicator 12 hasfirst and second ends 14 and 16. Its basic components include a base 18,a product cup 20, and an applicator pad 22 (not visible in FIG. 2),overlaid by a protective cover 24. The product cup 20 contains aselected quantity of a liquid product (not shown). The quantity may bevaried as desired to suit a particular application, however in theillustrated example the quantity is sufficient for a single use or“dose” or “application” of the liquid product. As used herein, the term“liquid product” refers to any product in the liquid phase, regardlessof its viscosity or chemical characteristics. In the illustratedexample, the liquid product is a “liquid bandage” of a known type whichcures to create a polymeric seal when applied to a wound.

FIG. 3 illustrates the construction of the applicator 12 in more detail.The applicator 12 is built up from multiple layers. The bottom layer isthe base 18 which is constructed of a suitable material capable of beingmolded to shape, resisting the selected liquid product, and excludingair from the liquid product, for example paperboard, plastic, or metal.In the illustrated example the base 18 is constructed from a metallicfoil. The concave product cup 20 is molded near a first end 26 of thebase 18, and a recessed applicator cup 28 is molded near a second end 30of the base 18. In the illustrated example, the product cup 20 isgenerally lozenge-shaped and the applicator cup 28 is generallytriangular with planar sides. However, these shapes are not critical andmay be varied as desired.

A recessed channel 32 is molded into the base and connects the productcup 20 and the applicator cup 28. A first adhesive layer 34, for examplehot seal adhesive of a known type, is applied to the flat portions ofthe upper surface of the base 18. The product cup 20 is filled with theselected liquid product 36. A separator sheet 38 of a similar shape,size, and composition to the base 18 is coated on its lower surface witha second adhesive layer 40, for example hot seal adhesive of a knowntype. The separator sheet 38 is placed on top of the base 18 so that thefirst adhesive layer 34 is in contact with the second adhesive layer 40.The separator sheet 38 may include indicia 39 such as directions for useof the applicator 12. An applicator opening 42, similar in size andshape to the perimeter of the applicator cup 28, is formed in theseparator sheet 38. When the separator sheet 38 is placed over the base18, the applicator opening 42 is aligned with the applicator cup 20 sothat the applicator cup 20 is exposed.

An applicator pad 44 is placed in the applicator cup 20. The applicatorpad 44 may be constructed of any material which will absorb and retainthe liquid product 36, yet allow the liquid product 36 to be transferredto the skin by contact, for example natural or synthetic fibers, paper,sponge, or foam. The applicator pad 44 includes a tacky adhesive coating46 on the bottom surface thereof which is protected by a release liner48 until the applicator pad 44 is installed in the applicator cup 28.Alternatively, the applicator pad 44 could be attached to the applicatorcup 20 with a separately-applied adhesive.

The separator sheet 38 and the base 18 are sealed together by applyingheat and pressure to the mutually contacting surfaces thereof, causingthe first and second adhesive layers 34 and 40 to fuse and bondtogether. This process seals the liquid product 36 in the product cup20. At the same time, reduced levels of heat and pressure are applied tothe base 18 and the separator sheet 38 in an area 50 traversing thechannel 32, in order to form a so-called “weak weld” in a known manner.The weak weld closes off the channel 32 and separates the product cup 20from the applicator cup 28. However, the strength of the adhesive bondat the weak weld is not as strong as the adhesive bond between theremaining portions of the separator 18 and the base 38.

The cover 24, which has a third adhesive layer 52 on a lower surfacethereof, is bonded over the separator sheet 38 to cover the applicatorpad 44. This bonding operation may take place at the same time as thebonding operation described above, or afterwards. The central portion ofthe cover 24 at the first end 14 of the applicator 12 is bonded to theseparator sheet 38 more securely than the remainder of the cover 24 soas to form a hinge tab 54. The cover 24 may include further indicia 55thereon, such as instructions for removing the cover 24.

After the bonding operation is complete, the applicator 12 may betrimmed or die-cut to a desired shape. In the illustrated example, thecorners 56 and 56′ of the first end 14 of the applicator 12 are cut offat an angle (see FIG. 2) so that the applicator pad 44 will be exposedfor convenient use when the cover 24 is opened.

The above description has explained the construction process for asingle applicator 12. However, it is noted that a plurality ofapplicators 12 may be produced simultaneously by forming each of thelayers (e.g. the base 18, separator 28, and cover 24) in a sizesufficient for several individual applicators 12 and performing theabove-described assembly steps for a plurality of applicators 12simultaneously, resulting in sheets 10 of selected numbers ofapplicators as shown in FIG. 1. The individual applicators 12 may thenbe separated for use by cuffing them apart or otherwise separating themalong perforations P.

The applicator 12 is used as follows. First, the applicator 12 isremoved from the external packaging (if present) and separated from theother applicators 12. The cover 24 is then grasped, peeled back, andfolded behind the base 18, exposing the applicator pad 44, as shown inFIGS. 4 and 5. The hinge tab 54 retains the cover 24 attached to theapplicator 12. The product cup 20 is then pressurized by squeezing itand pressing on the area marked by the indicia 39. The pressurizedliquid product 36 breaks the weak weld and flows through the channel 32into the applicator cup 28, where it saturates the applicator pad 44.The applicator pad 44 may then be used to apply the liquid product 36 toa desired area, for example a burn or wound, by using the applicator 12as a handle. Once the application is complete, the applicator 12 may bediscarded or recycled, leaving a minimal amount of waste packaging.

The foregoing has described a liquid applicator and a method for itsproduction. While specific embodiments of the present invention havebeen described, it will be apparent to those skilled in the art thatvarious modifications thereto can be made without departing from thespirit and scope of the invention. Accordingly, the foregoingdescription of the preferred embodiment of the invention and the bestmode for practicing the invention are provided for the purpose ofillustration only and not for the purpose of limitation.

1. An applicator for a liquid product, comprising: an elongated basewhich includes: a product cup sized for retaining a single-dose quantityof a liquid product; an applicator cup for receiving an applicator pad;a channel interconnecting the product cup and the applicator cup; anabsorbent applicator pad disposed in the applicator cup; and cover forpositively retaining a liquid product in the product cup until it isdesired to apply the liquid product.
 2. The applicator of claim 1wherein the means for retaining the liquid product comprise a weak weldformed in the channel between the product cup and the applicator cup. 3.The applicator of claim 1 wherein: the base is a sheet-like memberhaving the product cup, applicator cup, and channel formed therein; anda separator sheet is attached to the base so as to enclose the productcup and channel while leaving the applicator cup at least partiallyexposed.
 4. The applicator of claim 3 wherein: the base and theseparator sheet each comprise a metallic foil; and the base and theseparator sheet are bonded together with an adhesive layer.
 5. Theapplicator of claim 3 wherein the weak weld is defined by correspondingportions of the base and the separator sheet aligned with the channelwhich are attached together less securely than the remainder of the baseand the separator sheet.
 6. The applicator of claim 3 wherein theapplicator extends through an opening in the separator sheet.
 7. Theapplicator of claim 1 wherein the product cup is disposed at a first endof the base and the applicator cup is disposed at a second end of thebase.
 8. The applicator of claim 7 wherein a portion of the base whichsurrounds the applicator pad is narrowed so as to expose the applicatorpad for convenient use when the cover is opened.
 9. The applicator ofclaim 7 wherein; the applicator pad includes a pair of angled sides; andopposed corners of the base at the second end thereof are angled tocorrespond to the shape of the applicator pad.
 10. The applicator ofclaim 6 wherein opposed corners of the base at the second end thereofare angled to provide access to the applicator pad.
 11. The applicatorof claim 1, wherein the cover is removably attached to the applicatorsand is adapted to protect the applicator pad from exposure until thecover is intentionally opened.
 12. The applicator of claim 9 wherein: aportion of the cover is attached to the applicator more securely thanthe remainder of the cover so as to define a hinge tab which remainsattached to the separator sheet when the remainder of the cover isopened.
 13. The applicator of claim 1 further comprising a liquidproduct disposed in the product cup.
 14. The applicator of claim 13wherein the liquid product is a liquid bandage material.
 15. A method ofmaking an applicator for a liquid product, comprising: providing anelongated base: molding a product cup sized for retaining a single-dosequantity of a liquid product in the base; molding an applicator cup forreceiving an applicator pad in the base; molding a channelinterconnecting the product cup and the applicator cup in the base;placing an absorbent applicator pad in the applicator cup; disposing aliquid product in the product cup; and sealing the liquid product in theproduct cup such that it will be retained therein until it is desired toapply the liquid product.
 16. The method of claim 15 wherein the step ofsealing the liquid product comprises forming a frangible divider in thechannel between the product cup and the applicator cup.
 17. The methodof claim 15 further comprising attaching a separator sheet to the baseso as to enclose the product cup and channel while leaving theapplicator cup at least partially exposed.
 18. The method of claim 17further comprising: providing the separator sheet with a first layer ofhot seal adhesive; and providing the base with a second layer of hotseal adhesive; and applying heat and pressure to the separator sheet andthe base to bond the adhesive layers together.
 19. The method of claim18 wherein a weak weld is formed by bonding a selected area of the baseand the separator sheet which is aligned with the channel together,wherein the selected area is bonded together less securely than theremaining bonded portions of the base and the separator sheet.
 20. Themethod of claim 15 further comprising removably attaching to theseparator sheet a cover which overlies the applicator pad and protectsit from exposure.
 21. The method of claim 15 further comprisingattaching a portion of the cover to the separator sheet more securelythan the remainder of the cover so as to define a hinge tab whichremains attached to the separator sheet when the remainder of the coveris opened.